F R A U N H O F E R I N S T I T U T E F O R M A N U FA C T U R I N G T E C H N O L O G Y A N D A D VA N C E D M AT E R I A L S I F A M

CASTING TECHNOLOGYFROM IDEAS TO PRODUCTS

WE UNDERSTAND MATERIALS

C O N T E N T S

C A S T I N G T E C H N O L O G Y 3

C A S T I N G T E C H N O L O G I E S F O R C U S T O M I Z E D C A S T I N G S 4

H Y B R I D C A S T I N G A N D F I B E R I N T E G R A T I O N 6

C O M P L E X C A S T I N G S 8

M A R K I N G O F C A S T I N G S A N D S E N S O R I N T E G R A T I O N 1 0

C O M P O N E N T S F O R E L E C T R I C M A C H I N E S 1 2

N U M E R I C A L S I M U L A T I O N 1 5

T E C H N O L O G Y C O N S U L T I N G 1 7

O U R O F F E R 1 8

L O C A T I O N S 1 9

and plant construction, electronics and electrical engineering,

shipbuilding, rail vehicle manufacture, the packaging industry,

and the construction sector.

Fraunhofer IFAM has a highly qualified workforce of more

than 600 people, organized into project teams and business

segments covering specific topics. These topics include mate-

rials, shaping, joining technologies, surface functionalization,

and the development of complete components and complex

systems. This means that Fraunhofer IFAM covers the whole

value-creation chain from the development of materials and

product design up to the integration into industrial production

– including pilot trials and customized workforce training in

new technologies.

C O R E C O M P E T E N C I E S

Fraunhofer IFAM is a material science research institution with

an emphasis on metallic and polymeric materials. We have

focused our extensive scientific knowledge and technological

expertise in seven core competencies. Each of these core com-

petencies – either by itself or all together – are the cornerstones

of our success in the R&D market and the basis for future

innovations.

| Powder technology

| Sintered, composite, and cellular metallic materials

| Adhesive bonding technology

| Surface technology

| Casting technology

| Electrical components and systems

| Fiber reinforced plastics

T H E F R A U N H O F E R - G E S E L L S C H A F T

The Fraunhofer-Gesellschaft promotes and carries out applied

scientific research and development work. Founded in 1949,

the work of the Fraunhofer-Gesellschaft is geared to the needs

of industry and society. Our contract partners and customers

are companies in the manufacturing and service sectors as

well as public organizations. The Fraunhofer-Gesellschaft

currently operates 66 institutes in Germany and employs

more than 24,000 people, most of whom are scientists and

engineers.

The institutes of the Fraunhofer-Gesellschaft also work togeth-

er: They collaborate in groups and alliances and, depending on

the needs of particular projects, they are also able to bundle

their expertise in flexible structures. The Fraunhofer Institute

for Manufacturing Technology and Advanced Materials IFAM

is involved in ten alliances, the Fraunhofer Group for Materials

and Components – MATERIALS, and the Fraunhofer Academy.

F R A U N H O F E R I F A M

Fraunhofer IFAM is one of the leading independent research

organizations in Europe in the fields of “Adhesive Bonding

Technology and Surfaces” and “Shaping and Functional

Materials”. The focus of all the R&D activities is to provide

customers with effective, application-oriented solutions. Most

of the products, processes, and technologies we develop

are for sectors where sustainability is particularly important,

namely for the aviation industry, automotive sector, energy

and environment, medical technology and life sciences. The

solutions developed at Fraunhofer IFAM are, however, also

used in various other branches of industry including machinery

2

From ideas to products

With our core competence Casting Technology, the Fraun-

hofer IFAM supports industrial clients in transforming an idea

from first prototype to ready-to-use product through casting.

As a research and development partner for applied industrial

research, we can provide the correct service, whether through

technical feasibility studies, consultancy, prototype manufac-

ture, examination of commercial viability considerations, or

fault and process analysis. Fitting different issues Fraunhofer

IFAM provides several casting processes and materials.

Different casting methods and materials are available to suit

every application. As well as our many years of experience,

important elements of this core competence include the pro-

cess and systems technology established at Fraunhofer IFAM

for high pressure die casting and low pressure casting, lost

foam, investment and sand casting, as well as our numerical

simulation, comprehensive analysis and materials testing.

Going beyond the classic issues of casting technology, we

also help our clients find solutions to their interdisciplinary

production and materials engineering requirements. Here,

project teams from a variety of disciplines, such as com-

posite materials, powder technology and adhesive bonding

technology and surfaces, work together to find scientific

and application-oriented answers to questions of corrosion,

surface treatment, painting or adhesive bonding. This allows

us to develop completely new combinations of technologies

and material applications.

CASTING TECHNOLOGY

Apart from providing advice on casting technology and

customized projects, our research is also focused on the

following key aspects:

| Hybrid casting and fiber integration

CFRP-aluminum hybrid casting

Integration of fiber and wire reinforcement structures into castings

| Complex castings

Salt cores and lost core technologies

Lost foam and investment casting for the production of

highly complex geometries

| CASTTRONICS® – RFID marking for castings and

sensor integration

Marking of castings using RFID transponders

Structural health monitoring through sensor integration

| Components for electric machines

Cast coils

Castings for electric motors

Contact Casting Technology

Dipl.-Ing. Franz-Josef Wöstmann MBA

Head of department

Phone +49 421 2246 -225

franz-josef.woestmann@ ifam.fraunhofer.de

Dipl.-Wi.-Ing. Christoph Pille

Group leader

Phone +49 421 2246-227

christoph.pille@ifam.fraunhofer.de

1 Foaming of casting models for the lost foam casting process.

2 High pressure die casting part with complex geometry.

21

3

The casting pilot plant at Fraunhofer IFAM provides a wide

range of casting processes that can be flexibly applied. An

availability of industrial series production scale is typical at

Fraunhofer and offers the best preconditions for the success-

ful completion of research and development projects. The

materials cast include aluminum, magnesium, zinc, copper,

steel and special customized alloys. Furthermore, we also

develop and improve special materials such as metal-matrix

composites, hence opening up new fields of application for

casting processes and castings. Numerical simulation of the

casting processes and comprehensive analysis round out the

competencies.

High pressure die casting

High pressure die casting (HPDC) is characterized by very high

productivity and reproducibility. At Fraunhofer IFAM, HPDC

cold chamber technology is available for this. In addition to

conventional castings, parts with permanent and lost cores –

for example salt cores – are developed, fiber, wire and CFRP

structures are integrated using the hybrid casting process,

porous materials such as ceramics are infiltrated with metal

CASTING TECHNOLOGIES FOR CUSTOMIZED CASTINGS

alloys and RFID transponders for the marking of castings are

directly cast into the parts.

Low pressure casting

During low pressure casting, the melt is fed laminar under

controlled conditions, allowing the production of castings

which the highest quality demands, with reduced porosity

and without oxide inclusions. The flexibly configurable low

pressure casting plant at the institute allows a wide array of

different alloys, such as aluminum, magnesium, cast iron,

steel and copper, to be cast into different mold materials such

as steel dies or sand and ceramic molds. Indirect inductive

heating also enables individual special materials, such as salt

mixtures, to be cast.

Us ing s tate -of-the -ar t cas t ing equipment, our sc ient is t s and technologis t s develop customer-speci f ic

so lut ions . F lex ib le team s truc tures combining a wide range of technology competencies are an impor t-

ant fac tor for our success in developing innovat ive cas t produc t s and reaching new market segments .

Here, we pursue new approaches, opt imiz ing our c lass ic cas t ing technology even fur ther through the in -

tegrat ion of func t ions, whi ls t constant ly keeping in mind the demands of industr ia l produc t ion and the

need to conser ve resources .

1

Lost foam

Lost foam technology enables complex parts to be cast direct-

ly to near-net shape in one piece. This complexity is achieved

by joining polymer foam segments to form a lost-casting

pattern, allowing complex castings with internal cooling

ducts or complicated undercuts to be produced. During the

casting process, the thermal energy of the melt decomposes

the pattern material and fills the resulting voids in the mold,

producing a cast which is true to detail. Our lost foam casting

pilot plant – unique in Europe – offers the full process chain

for the production of casting models by rapid prototyping

or near-series foaming, through to the casting of aluminum,

steel, cast iron or special customised alloys for research and

development projects. This allows the development of new

castings (e.g. engine housings with complex cooling ducts) as

well as the production of prototypes and functional specimens

right up to pre-production series. Fraunhofer IFAM is a leading

research partner in lost foam technology and works closely

with the industry through the association named Lost Foam

Council e V.

Investment casting

The production of particularly demanding and filigreed

structures with high-quality surfaces is possible using

investment casting. At Fraunhofer IFAM, wax models for

investment casting can be produced by wax injection molding

or rapid prototyping. The models are subsequently fitted with

a gating system, formed in ceramic or plaster-based bedding

compounds and melted – thus creating the precision mold in

a block molding process. Various investment casting plants are

available for casting on which various, for example aluminum

and copper-based, alloys, but also special alloys and pure

metals can be cast.

Sand casting

Sand casting is carried out through a hand-molding process.

It is suitable for a wide variety of geometries, from simple to

complex, thanks to its use of lost cores. Wooden or metal

models are used for mo ld production.

www.ifam.fraunhofer.de/casting

1 Firing of casting molds for investment casting using the block

molding process.

2 Casting of steel melts by sand casting with sand cores

(© sorapolujjin/Fotolia).

3 Bühler SC N/66 cold chamber HPDC machine in the casting pilot

plant at Fraunhofer IFAM (© GFG/Thomas Kleiner).

32

4 | 5

1

Hybrid casting of CFRP-aluminum composites

In line with the latest lightweight construction developments,

demand is growing for highly integrated lightweight

structures and new concepts for multi-material design. Joining

technology for castings that incorporate different types of

lightweight material plays a particularly important role here.

New solutions for different types of joint between two

such lightweight materials, aluminum and CFRP, are being

developed at Fraunhofer IFAM. A transitional structure of

glass fibers or heat-resistant plastic between the aluminum

and CFRP materials to be joined forms a connection between

the metal and the fiber composite material, while taking

account of fiber-compatible design and allowing a galvanic

decoupling between the CFRP and aluminum materials in

order to avoid electrochemical corrosion effects. Compared

with conventional joining techniques, this offers the benefits

of a reduced installation space and at the same time lower

weight. In the event of damage to the fiber composite part,

the cast metallic connection areas can be easily separated,

HYBRID CASTING AND FIBER INTEGRATIONCREATING BONDS AND INCREASING MECHANICAL STRENGTHS

and the fiber composite part can be easily replaced using the

metallic connecting elements.

Fiber integration

The integration of reinforcing fibers is an established tech-

nology for increasing mechanical properties, such as tensile

strength or rigidity, in the molding of plastics. Working on

this basis, Fraunhofer IFAM is developing processes suitable

for series production for the integration of glass, ceramic or

carbon fibers into castings directly during casting. The fibers

can thereby be integrated into the whole casting or only

locally into selected areas. The particular challenges here lie in

the application-specific choice and design of the fiber system,

so as to ensure an optimum bond between the fibers and the

casting matrix, and the exact positioning of the fibers in the

casting mold and in the later casting.

“Hybr id cas t ing and f iber integrat ion” deals with the mater ia l integrat ion of f iber and wire s t ruc tures

into cas t ings in order to opt imize and inf luence their mechanical proper t ies , and the jo ining – by cas t-

ing – of f iber composi tes and cas t metal, in par t icular CFRP with cas t a luminum. The chal lenges here l ie

both in the posi t ioning and f ix ing of the f iber and wire intermediates in the cas t ing mold, the inf i l t ra -

t ion behav ior and the necessar y appl icat ion of a pre load, and in the achievement of a substance -to -sub -

s tance bond between the cas t metal and the f iber or wire s t ruc ture. F iberglass s t ruc tures are general ly

used to jo in the cas t ing and f iber composi te. Mechanical proper t ies are preferably opt imized us ing f iber

s t ruc tures to increase r ig id i t y or by means of wire s t ruc tures to improve frac ture behav ior and fa i l - safe

behav ior in the event of damage.

2

43

Wire reinforcement

A method for improving the mechanical properties of light

alloy castings for highly stressed components has been de-

veloped in cooperation with the “Cellular Metallic Materials”

department. Local integration of 3D wire structures into the

casting can significantly improve not only the high-tempera-

ture strength, but also the impact resistance and the fracture

behavior of aluminum and magnesium castings, with only a

slight increase in density. The resulting increase in mass-spe-

cific material properties allows an adapted fail-safe function

to be incorporated in the casting. Both the wire reinforcement

materials used and the mesh sizes can be significantly varied

so that the properties of the castings can also be flexibly

adapted to the application. The main challenges facing the

integration of reinforcing structures are ensuring the optimum

substance-to-substance bond between the reinforcing struc-

ture with the casting matrix and ensuring that the right choice

of the materials used.

Functional integration – cast embedding of inlays

The term “functional integration” refers to the integration by

casting of small parts or connecting elements such as sleeves,

tubes, threaded inserts or studs. The challenges for successful

integration directly into the casting lie in the positioning of

the inlay in the casting mold, automation of the preparation

and feed of the inlays and ensuring a positive, non-positive or

substance-to-substance bond with the casting matrix.

Contact Hybrid Casting

Robin van der Auwera M.Sc.

Project leader

Phone +49 421 2246-178

robin.auwera@ifam.fraunhofer.de

Dipl.-Ing. Jan Clausen

Project leader

Phone +49 421 2246-273

jan.clausen@ifam.fraunhofer.de

Dr.-Ing. Marco Haesche

Project leader

Phone +49 421 2246-119

marco.haesche@ifam.fraunhofer.de

www.ifam.fraunhofer.de/hybridcasting

1 CFRP-aluminum hybrid bond with fiberglass laminate integrated

into aluminum by casting as a transitional material.

2 Ceramic fiber-aluminum hybrid bond produced by aluminum

high pressure die casting.

3 Reinforced light alloy by integration of 3D wire structures.

4 Microsection of a hybrid casting matrix with infiltrated glass

fibers produced by aluminum high pressure die casting.

6 | 7

1 2

Lost cores – hollows without slide gate technology

One major research topic is the development of lost cores

(non-permanent cores). With casting methods such as high

pressure die casting, gravity die casting or sand casting, com-

plex geometries can only be produced using lost cores. High

demands are placed on these cores, particularly those used

in high pressure die casting. These include the need for high

strength so as to withstand the casting process undamaged.

At the same time the cores have to be easy to remove from

the cast part afterwards. Fraunhofer IFAM is developing new

methods for the production of lost cores made from a variety

of materials and for use in different casting processes.

One possibility here is the use of cast salt cores, which are

strong enough to withstand even the high pressure die casting

process thanks to their high thermal and mechanical stability.

In the Casting Technology competence field, we are develop-

ing new methods of producing salt cores by casting, as well as

customized salt mixtures for improving casting and mechanical

properties. Prototypes and functional specimens for salt cores

are available, as is the planning and conducting of pilot series.

Furthermore, we are pursuing innovative technologies for core

production in which no melting of the salt mixtures is neces-

sary.

The main research focus in the “lost cores” field addresses the

key aspects:

| Development of alternative production methods and

materials for lost cores| Production of salt cores using the low pressure casting,

lost foam and die casting processes| Casting simulation of cast salt cores| Characterization of salt cores (casting properties, micro-

structure, mechanical testing, pore analysis, shrinkage

properties)| Casting of salt cores using different metal casting methods| Technologies for dissolving and removing the cores

Contact Complex Castings

Michael Heuser M.Sc.

Project leader

Phone +49 421 2246-118

michael.heuser@ifam.fraunhofer.de

At Fraunhofer I FAM, we are developing technologies to a l low the produc t ion of cas t ings with complex

geometr ies that could not be produced by cas t ing in the convent ional manner due to poor demold-

abi l i t y, compl icated undercut s or integrated hol lows.

1 Salt cores of different salt mixtures produced by die casting.

2 Examination of salt cores in the bending test.

COMPLEX CASTINGSTHE RIGHT CASTING PROCESS FOR ANY GEOMETRY

Casting technologies with lost model patterns and molds

Complex castings with demanding geometric details can be

produced in a variety of metal alloys using the lost foam, in-

vestment casting and low pressure casting methods. The

lost foam and investment casting processes, in particular, pro-

duce extremely complex parts in near-net-shape directly from

the mold without burrs or the need for labor-intensive de-cor-

ing. All three methods are suitable for the fast production of

one-off parts, prototypes and functional specimens, and can

also be easily implemented in industrial series production.

The lost foam method offers outstanding possibilities for the

production of medium to large castings that at the same time

have complex geometries as a result of undercuts and inte-

grated hollows or ducts. This complexity is achieved by joining

polymer foam segments to create a uniform model. During

the casting process, the thermal energy of the melt decompos-

es the model material and fills the resulting voids in the mold

producing a cast which is true to detail. As a result the melt

forms an exact geometric image of the model.

Investment casting is particularly suitable for the produc-

tion of small parts with complex geometries and outstanding

surface finishes. Wax model patterns – the basis for the lost

ceramic molds – are produced by injection molding or rapid

prototyping. In the furnace the wax is melted out and the

mold preheated ready for casting. Casting is performed with

differential pressure and under inert gas so that not only stan-

dard melts but also special alloys and pure metals can be pro-

cessed. Fraunhofer IFAM uses the investment casting method

to produce parts with close dimensional tolerances, very good

surface finishes and pronounced details.

The flexibly configurable low pressure casting plant at the

institute allows a wide array of different melts such as alu-

minum, magnesium, cast iron, steel and copper to be cast

into different mold materials such as steel, sand and ceramic

molds. The combination of different mound materials – pre-

dominantly sand or ceramics – in conjunction with a wide va-

riety of materials that can be used in lost cores allows complex

castings with high quality demands and dense microstructure

to be produced by low pressure casting.

Contact Lost Foam

Dipl.-Ing. Jan Clausen

Phone +49 421 2246-273

jan.clausen@ifam.fraunhofer.de

Dipl.-Ing. (FH) Daniela Pille M.Sc.

Phone +49 421 2246-108

daniela.pille@ifam.fraunhofer.de

Contact Investment Casting

Dipl.-Ing. (FH) Daniela Pille M.Sc.

Phone +49 421 2246-108

daniela.pille@ifam.fraunhofer.de

Dipl.-Wi.-Ing. Thomas Rahn

Phone +49 421 2246-219

thomas.rahn@ifam.fraunhofer.de

Contact Low Pressure Casting

Dr.-Ing. Marco Haesche

Phone +49 421 2246-119

marco.haesche@ifam.fraunhofer.de

Michael Heuser M.Sc.

Phone +49 421 2246-118

michael.heuser@ifam.fraunhofer.de

3 Lost foam pattern for casting of a stator housing for a wheel hub

motor.

4 Cast housing with integrated water jacket and cooling ducts for

an electric motor.

43

8 | 9

1

RFID marking for metal castings

Until now the marking of metallic castings has been limit-

ed to conventional methods such as barcode or data matrix

code (DMC). At Fraunhofer IFAM, RFID transponders are

integrated into castings enabling an electronic, radio-based

marking and identification of cast products. The RFID tran-

sponder can be applied later to existing castings, but also

integrated into the casting directly during casting using the

patented CASTTRONICS® process.

The established RFID technology stands for an electronic,

contact-free and smart identification of products and compo-

nents (RFID = Radio Frequency ID) and is regarded as a logical

further development of marking methods used to date. The

RFID transponder has a globally unique serial number and can

also be expanded to include customized codes in order to en-

sure unambiguous marking. RFID functions by radio, requires

no visual contact, is reliable and practically invisible - and thus

offers benefits for industrial applications:

| Electronic encoding without optical marking features| Simultaneous identification of several castings possible| Resistant to rugged industrial environments and soiling or

damage to the surface of the casting| Higher security of the data integrity and scanning quota

MARKING OF CASTINGS AND SENSOR INTEGRATION

| Encryption of the information is possible| Counterfeit protection for castings| VDA-conformant encoding

The casting is already unambiguously marked on removal

from the mold and can no longer be confused. Counterfeit-

ing is also no longer possible. Damage, loss or manipulation

– with the CASTTRONICS® technology the encoding of the cast-

ing is protected. By contrast with visual marking methods,

parts with integrated transponder are still clearly identifiable

even after surface treatment, e.g. due to coating, blasting or

soiling.

The transponder cast into the casting offers not only the pure

identification but also a counterfeit protection function as

an electronic seal of authenticity against product piracy and

confusion. The integrated chip can no longer be removed

without visible damage to the casting, and replacement is not

possible.

Fraunhofer IFAM supports the foundry industry with the

pro-active, early entry into the RFID technology. If a few cen-

timeters of scanning range are sufficient, the robust system

frequency 125 kHz (LF) predominant in the metal industry to

date is used. The next technological step is now being taken

with the use of the 868 MHz (UHF) frequency to increase the

scanning range for castings with integrated RFID transponder

to up to one meter.

The C AST TRON ICS® technology a l lows direc t integrat ion of e lec tronic and adaptronic func t ional e lements

into cas t ings dur ing the die cas t ing process . This of fer s a wider range of e lec tronic , sensor or ac tuator

func t ions by compar ison with convent ional cas t ings .

32

1 Casting with integrated UHF-RFID transponder for large

scanning distances.

2 Die casting with cast-in integrated RFID transponder and hand-

held scanner.

3 Belt conveyor with UHF RFID scanning system for identification

of castings in a fully automated production and assembly line.

10 | 11

Structural health monitoring with integrated sensors

Sensors cast into the part allow mechanical loads in the part

such as compressive and tensile forces, deformations or vi-

brations to be detected, measured and assessed. Due to the

integration during the casting process, the sensors can be

embedded into the part directly at the point where the loads

occur in order to warn of overloading or damage to the part.

This enables structural health monitoring, a crucial benefit

particularly for safety components. Furthermore, the vibration

behavior of components and their acoustics can be actively

influenced by integrated piezo actuators (“structural health

control”).

Conventional sensors for monitoring the load state of com-

ponents and their deformation – for example, strain gauges

– have to be applied to the surface of a part. Integrated sen-

sors cast into the part offer the benefit that after the casting

process, they are protected against soiling, damage or loss

– both for further mechanical machining processes on the

casting, during assembly and during operation. In addition,

the integration during casting allows an optimum bond to

be created between the sensor elements and the material

structure. Additional machining and joining processes for

application of the sensors can be eliminated.

Contact CASTTRONICS®

Dipl.-Wi.-Ing. Christoph Pille

Group leader

Phone +49 421 2246-227

christoph.pille@ifam.fraunhofer.de

Dipl.-Wi.-Ing. Thomas Rahn

Project leader

Phone +49 421 2246-219

thomas.rahn@ifam.fraunhofer.de

www.casttronics.de

1 2

Cast coils

Cast coils offer excellent potential for boosting the perfor-

mance of electric machines. An integrative production meth-

od developed at Fraunhofer IFAM is employed for the manu-

facture of these innovative components. Fields of application

are to be found in particular in electric motors for cars and

commercial vehicles, for industrial drives and in high-efficiency

generators.

This method allows us to produce the coil geometries with a

flat conductor arrangement, which offer significant advantag-

es compared with conventionally produced wound coils. Pro-

duction by casting allows a specific and individual adaptation

of the conductor cross-section, allowing maximum use to be

made of the installation space available in electric motors. This

allows slot-filling factors of over 80 percent to be achieved,

while at the same time reducing electrical resistance by up to

50 percent. New cooling concepts made possible by flat con-

struction also enable a further increase in the current density.

The feasibility and technological benefits of cast coils have

already been demonstrated in various applications.

COMPONENTS FOR ELECTRIC MACHINESMOBILITY THROUGH CASTING

Depending on the size and number of coils to be produced,

different casting methods can be employed. In investment

casting, low conductor heights (> 0.7 mm) can be achieved

with coil lengths of up to 200 mm, while coils produced using

the lost foam method can have edge lengths of up to 1 me-

ter. For large quantities, production of the coils in permanent

molds results in the lowest unit costs. A complete investment

casting process chain is available for the production of proto-

types and small pre-production series made of aluminum and

copper.

Through intensive cooperation with our departments from

the fields of surface technology, in particular “Adhesion and

Interface Research” and “Paint/Lacquer Technology”, cus-

tomized insulation coatings can be developed, implemented

and optimized. In this way we can satisfy the electrical and

thermal specifications of our clients with respect to insulation

strength, minimizing the coating thickness and increasing the

heat resistance and aging resistance, with a minimum of de-

velopment time.

Elec tromobil i t y is a topic that is gaining in impor tance, not least in the area of cast ing technology, lead-

ing to increasing demand for the development of new cast components. The focus is on cast ings for

elec tr ic dr ives and motor vehicles. The close interdiscipl inar y cooperat ion between the “Elec tr ic Drives”

depar tment and our other depar tments creates an optimum know-how constel lat ion, al lowing the holis t ic

considerat ion of production engineering aspects with a pr imary focus on cast ing, engineering planning

and elec tromagnetic design for the successful production of components for elec tr ic machines.

43

1 Fraunhofer wheel hub motor for demonstration of cast

components on the Frecc0 electric vehicle.

2 Cast coils of aluminum or copper produced by investment

casting.

3 Stator of a wheel hub motor with cast aluminum coils arranged

in a ring.

4 Schematic drawing of a wheel hub motor with cast stator and

rotor for series production.

12 | 13

Castings for electric machines

Particular importance is attached to the development of cast

components for electric drives. The requirements for a later

transfer to series production are taken into account at all

times. The main focus is on actively or passively cooled hous-

ings and on metal melt-infiltrated rotors and laminated stacks.

The most suitable casting method for the application is cho-

sen and where necessary, additional technologies such as lost

cores are employed. The lost foam method is used for produc-

tion of the housing components as it allows highly complex

constructions to be created and internal cooling ducts for coils

or power electronics can also be directly integrated into the

casting.

Apart from casting production, pilot applications and tests of

electric motors are also available at Fraunhofer IFAM. Com-

plete electric motors can be designed at the institute and

checked on test stands and in operation in various demonstra-

tor vehicles under dynamic driving conditions.

Contact Casting Technology

Dipl.-Ing. Franz-Josef Wöstmann MBA

Head of department

Phone +49 421 2246-225

franz-josef.woestmann@ifam.fraunhofer.de

Dipl.-Wi.-Ing. Christoph Pille

Group leader

Phone +49 421 2246-227

christoph.pille@ifam.fraunhofer.de

1

32

Mold filling and solidification simulation

The simulation of mold filling and solidification is an useful

instrument for the design of casting molds which is both

cost-effective and time-efficient. Fraunhofer IFAM uses the

industrial standard software programs for casting simulation.

The goal of the simulation, apart from the mold design, is to

optimize the process parameters and to determine the final

product properties (e.g. localized discontinuity distribution).

Integrated computational materials engineering (ICME)

Casting simulation is considered in ICME as a link in the chain

of the whole product lifecycle. It allows, for example, the

influence of casting pores on the crash behavior of motor

vehicle parts to be investigated. Stochastic material models

are developed which allow statistical distributions of the local

material properties (e.g. elongation at break) to be described.

These models can be used in the conventional structural analy-

sis programs (FEM) which are also available at Fraunhofer IFAM.

Lightweight construction through robust design

Lightweight construction faces the challenge of producing

technical components with a high rigidity and low weight.

Apart from lightweight designs and materials, new methods

of hybrid lightweight construction (e.g. aluminum-CFRP struc-

tures) are now opening up new possibilities for further opti-

mization. At the institute, a method has been developed for

this, based on biological bone remodeling processes that dis-

tribute different material phases in the part in such a way that

maximum rigidity is achieved. This allows us to take statistical

variations and uncertainties into account when drawing up

design guides for the use of cast structures in hybrid parts

(robust design).

Contact Numerical Simulation

Andreas Burblies

Phone +49 421 2246-183

andreas.burblies@ifam.fraunhofer.de

Natalia Voßmeyer

Phone +49 421 2246-236

natalia.vossmeyer@ifam.fraunhofer.de

Fraunhofer Alliance SIMULATION

Andreas Burblies

(Contact person and head of office)

www.simulation.fraunhofer.de

1 Cast aluminum car body node.

2 Mold filling and solidification simulation.

3 Micro-CT porosity (© Fraunhofer IIS/EZRT).

14 | 15

NUMERICAL SIMULATIONLOOKING AHEAD

1

32

Consultancy and Feasibility Studies

With range of competencies and expertise of the staff at

Fraunhofer IFAM, we are able to put together interdisciplinary

project teams to provide the client with the advice required.

We advise our clients on every aspect from the right design

and dimensioning of the part for casting through the evalu-

ation and choice of suitable casting methods and materials

through to the testing of pre-series production processes.

Fault and Process Analyses

Faulty castings or problems in processes can have a vast

array of causes with often complex interrelationships. Our

experts have many years of experience with different casting

methods and materials, their idiosyncrasies and the resulting

demands. We collaborate with the customer to evaluate and

analyze problems, investigate the causes and then develop

appropriate solutions and measures.

Workshops and Personnel Qualification

The application of new technologies and materials in creat-

ing new products and their transfer to existing processes in

series production can only be successful if the personnel are

also correspondingly qualified. The personnel qualification

provides an important technology transfer during which the

latest scientific findings and methods become established in

industrial practice and younger staff become qualified.

Seminars on our research topics and casting principles are

equally as possible as customized workshops customized

individually to your wishes of the needs of the project. The

know-how conveyed can be further deepened by practical

demonstrations in the casting pilot plant, the application of

new materials and technologies can be tested and the effi-

cient use of the different casting methods trained.

1 The casting technology building at Fraunhofer IFAM.

2 Workshop on casting design.

3 Consultancy meeting as part of a fault and process analysis.

16 | 17

TECHNOLOGY CONSULTINGRESEARCH AND DEVELOPMENT FROM A SINGLE SOURCE

www.ifam.fraunhofer.de/casting

OUR OFFERHAVE YOU GOT AN IDEA AND ARE LOOKING FOR THE RIGHT PARTNER

FOR IMPLEMENTING IT?

product. It goes without saying that you can count on us for

complete confidentiality.

Through collaborations with other competence centers at

Fraunhofer IFAM during the project, we can provide answers

to any further questions you might have. Examples of success-

ful projects we have undertaken include development and of,

amongst others, the localized plasma coating of castings for

corrosion protection, the bonding of coatings using pre-appli-

cable adhesives, and electrical insulation protection coatings

for cast coils for use in automotive electric motors.

Quality testing and analysis| X-ray testing and CT| Alloy analysis| Electrical conductivity of alloys| Materialography and material testing| Measurement technology for recording thermophysical

data (temperature, thermal conductivity, heat of decom-

position, etc.)

Consulting and know-how transfer| Scientific project support and consultancy| Workshops| Personnel training

We offer our clients and project partners a broad range of

services customized individually to their needs, from consul-

tancy through project planning up to the implementation of

the project. We can support you in your development projects,

and also in the transfer of project results to existing processes.

With our interdisciplinary team of experienced scientists and

technologists, we can provide answers for all your questions.

We will work together to find innovative solutions and devel-

op concepts for the implementation of your idea, from the

start of the process right up to the completion of the finished

Technology consultancy in the processes| High pressure die casting| Low pressure casting| Lost foam casting| Investment casting| Sand casting

Experimental research & development| Feasibility studies and market analyses| Process and technology development| Material development for foundry materials| Casting of prototypes and functional specimens right up

to the pre-production series| Fault and process analysis| Numerical simulation

Casting Technology at Fraunhofer IFAM offers you research and development from a single source.

18

Institute Directors

Prof. Dr.-Ing. habil. Matthias Busse

Prof. Dr. Bernd Mayer

Fraunhofer Institute for Manufacturing Technology

and Advanced Materials IFAM

Wiener Strasse 12

28359 Bremen | Germany

Phone +49 421 2246-0

info@ifam.fraunhofer.de

www.ifam.fraunhofer.de

Winterbergstrasse 28

01277 Dresden | Germany

Phone +49 351 2537-300

info@ifam-dd.fraunhofer.de

Marie-Curie-Strasse 1–3

26129 Oldenburg | Germany

Phone +49 441 36116-262

info@ifam.fraunhofer.de

Ottenbecker Damm 12

21684 Stade | Germany

Phone +49 4141 78707-101

info@ifam.fraunhofer.de

Hermann-Münch-Strasse 1

38440 Wolfsburg | Germany

Phone +49 421 2246-126

info@ifam.fraunhofer.de

L O C A T I O N S A N D D E P A R T M E N T S

B R E M E N| Adhesion and Interface Research| Company audits in accordance with DIN 6701 | Adhesive

Bonding Technology| Business Development| Chemistry of Fiber Reinforced Plastics| Electrical Drive Systems| Energy System Analysis| Functional Printing| Casting Technology| Adhesives and Polymer Chemistry| Adhesive Bonding Technology| Paint/Lacquer Technology| Materialography and Analysis| Plasma Technology and Surfaces| Powder Technology| Technical Qualification and Consultancy| Workforce Training and Technology Transfer| Materials Science and Mechanical Engineering

D R E S D E N| Energy and Thermal Management| Sintered and Composite Materials| Cellular Metallic Materials| Hydrogen Technology

O L D E N B U R G| Electrical Energy Storage Systems

S T A D E| Automation and Production Technology

W O L F S B U R G| Lightweight Design and Electromobility

LOCATIONS

Follow us on

19

W W W. I FA M . F R A U N H O F E R . D E

Fraunhofer Institute for Manufacturing Technology and

Advanced Materials IFAM

Shaping and Functional Materials

Wiener Strasse 12

28359 Bremen

Phone +49 421 2246 -0

Fax +49 421 2246 -300

info@ifam.fraunhofer.de

Casting Technology

Dipl.-Ing. Franz-Josef Wöstmann MBA

Phone +49 421 2246 -225

franz-josef.woestmann@ifam.fraunhofer.de

© Fraunhofer Institute for Manufacturing Technology and

Advanced Materials IFAM